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Komatsu Wheeled Excavator PW160-7E0 Repair Service Manuals


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Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheeled Excavator PW160-7E0, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Wheeled Excavator PW160-7E0 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages: 1,023 pages
File Format: PDF
Language: English

VEBM395100 – Wheeled Excavator PW160-7E0 Shop Manual.pdf

MAIN SECTIONS
VEBM395100 PW160-7E0…..1
SAFETY…..3
SAFETY NOTICE…..3
IMPORTANT SAFETY NOTICE…..3
GENERAL PRECAUTIONS…..3
PRECAUTIONS DURING WORK…..4
01 GENERAL…..21
SPECIFICATION DIMENSION DRAWINGS…..22
DIMENSIONS…..22
1 pIECE BOOM…..22
WORKING RANGES…..24
1 PIECE BOOM…..24
2 PIECE BOOM…..25
SPECIFICATIONS…..26
WEIGHT TABLE…..28
1 piece boom…..29
2 piece boom…..30
FUEL, COOLANT AND LUBRICANTS…..31
10 STRUCTURE, FUNCTION AND…..33
ENGINE RELATED PARTS…..34
RADIATOR . OIL COOLER . CHARGE AIR COOLER…..35
POWER TRAIN…..36
SWING CIRCLE…..38
SWING MACHINERY & MOTOR…..40
SWING MOTOR…..44
Operation of swing lock…..48
RELIEF VALVE PORTION…..49
Operation…..49
UNDERCARRIAGE…..50
TRANSMISSION…..52
ATT EPC VALVE ASSEMBLY…..55
QUICK COUPLER CONTROL VALVE…..56
TRAVEL MOTOR…..58
OPERATION OF TRAVEL MOTOR…..60
CLUTCH CONTROL CIRCUIT…..62
AXLE…..64
SUSPENSION LOCK CYLINDER…..68
BRAKING SYSTEM…..70
BRAKE/STEER PUMP…..72
PRIORITY VALVE…..73
POWER BRAKE VALVE…..74
SPECIFICATIONS…..74
FUNCTION…..75
ACCUMULATOR for brake system…..76
STEERING SYSTEM…..78
STEERING COLUMN…..79
ORBITROL VALVE…..80
HYDRAULIC EQUIPMENT LAYOUT DRAWINGS…..81
HYDRAULIC CIRCUIT DIAGRAM…..84
HYDRAULIC TANK…..85
HYDRAULIC PUMP…..86
HPV125…..86
LS VALVE…..91
PC VALVE…..91
LS(pc)-EPC VALVE…..104
PILOT PRESSURE CONTROL (PPC) SYSTEM…..107
CONTROL VALVE…..108
PW160-7E0…..108
CLSS…..118
OUTLINE OF CLSS…..118
CENTre SWIVEL JOINT…..139
TRAVEL PPC PEDAL…..140
WORK EQUIPMENT . SWING PPC VALVE…..142
SOLENOID VALVE MANIFOLD…..146
SOLENOID VALVE BLOCK…..147
2 Position 3 way valve…..147
2 Position 4 way valve…..149
attachment epc valve…..151
BOOM SAFETY VALVE…..154
HYDRAULIC CYLINDER…..157
BOOM CYLINDER…..157
ARM CYLINDER…..157
BUCKET CYLINDER…..157
ADJUST CYLINDER…..158
OUTRIGGER CYLINDER…..160
DOZER CYLINDER…..162
WORK EQUIPMENT…..164
Work Equipment…..165
1. DIMENSION OF ARM…..167
2. Dimension of bucket…..168
AIR CONDITIONER…..169
air conditioner piping…..169
ELECTRICAL WIRING DIAGRAM…..170
ELECTRICAL SYSTEM…..171
Engine Control…..171
Engine controller…..173
CN-CE01 (*: Never connect to NC as malfunctions and errors occur)…..174
CN-CE01 (*: Never connect to NC as malfunctions and errors occur)…..174
CN-CE02 (*: Never connect to NC as malfunctions and errors occur)…..175
CN-CE03(*: Never connect to NC as malfunctions and errors occur)…..175
Engine throttle and pump controller…..175
ELECTRONIC CONTROL SYSTEM…..178
machine control system diagram…..179
MACHINE MONITOR SYSTEM…..202
MONITOR PANEL…..204
LIQUID CRYSTAL MONITOR ADJUSTMENT SWITCH…..223
OVERLOAD WARNING DEVICE…..230
OUTLINE…..230
SENSOR…..231
1st ATTACHMENT CIRCUIT HYDRAULIC PERFORMANCE (MAIN…..240
TRAVEL SYSTEM…..242
TRAVEL CIRCUIT…..242
oPERATIONAL AND CONTROL FEATURES…..243
Operators Input via travel mode switch…..243
OVERRUN PROTECTION. This is dealt with through the action of the counterbalance spool in the motor control block.When the machin……243
STEERING SYSTEM…..264
Operating principles…..264
Dynamic Steering…..264
2 – stage principle…..264
SERVICE BRAKE AND SUSPENSION SYSTEM…..277
bRAKING SYSTEM…..277
operation…..280
KOMTRAX terminal system…..282
KOMTRAX terminal…..283
20 TESTING AND ADJUSTING…..285
STANDARD VALUE TABLE FOR ENGINE RELATED PARTS…..286
STANDARD VALUE TABLE FOR CHASSIS RELATED PARTS…..287
Flow control characteristic of PC valve (STD)…..298
TESTING AND ADJUSTING…..299
Measuring engine speed…..300
Measuring intake air pressure (boost pressure)…..302
MEASUREMENT OF EXHAUST GAS COLOUR…..303
Adjusting valve clearance…..305
Measuring compression pressure…..307
MEASUREMENT OF BLOW-BY PRESSURE…..309
Measuring engine oil pressure…..310
CHECKING AND ADJUSTING AIR CONDITIONER COMPRESSOR BELT TENSION…..311
Replacing the fan belt…..312
Handling fuel system parts…..313
Releasing residual pressure from fuel system…..314
Measuring fuel pressure…..315
Measuring fuel discharge, return and leakage…..317
Bleeding air from fuel circuit…..321
Checking fuel circuit for leakage…..322
MEASUREMENT OF CLEARANCE IN SWING CIRCLE BEARINGS…..323
INSPECTION AND ADJUSTMENT OF HYDRAULIC OIL PRESSURE IN HYDRAULIC CIRCUIT FOR WORK EQUIPMENT, SWING AND TRAVEL…..324
INSPECTION AND ADJUSTMENT OF CONTROL CIRCUIT OIL PRESSURE…..327
Procedure for pressure reducing adjustment…..328
INSPECTION AND ADJUSTMENT OF PUMP PC (Valve INLET) CONTROL OIL PRESSURE…..329
INSPECTION AND ADJUSTMENT OF PUMP LS valve CONTROL OIL PRESSURE…..332
MEASUREMENT OF SOLENOID VALVE OUTPUT PRESSURE…..336
6 – Stage solenoid block…..338
4 – Stage solenoid block…..340
2 – Stage solenoid block…..341
MEASUREMENT OF PPC VALVE OUTPUT PRESSURE…..342
ADJUSTMENT OF WORK EQUIPMENT AND SWING PPC VALVE…..344
Measuring and adjusting quick coupler control valve output pressure…..345
testing travel motor relief pressure…..346
adjusting travel motor relief pressure…..347
Testing propshaft speed…..348
TESTING TRANSMISSION CLUTCH CONTROL CIRCUIT…..349
INSPECTION OF LOCATIONS OF HYDRAULIC DRIFT OF WORK EQUIPMENT…..351
RELEASE OF REMAINING PRESSURE IN HYDRAULIC CIRCUIT…..353
MEASUREMENT OF OIL LEAKAGE AMOUNT…..354
AIR BLEEDING OF VARIOUS PARTS…..356
INSPECTION PROCEDURES FOR DIODE…..358
SPECIAL FUNCTION OF MONITOR PANEL…..359
OPERATION OF OPERATORS MENU AND DISPLAY (OUTLINE)…..361
TABLE FOR FAILURE CODE NO…..368
OPERATION AND DISPLAY OF SERVICE MENU…..371
Way of switching to Service Menu…..371
Table for Monitoring Items…..374
Procedure for turning on KOMTRAX terminal…..391
KOMTRAX terminal lamp indications…..394
Preparation work for troubleshooting of electrical system…..397
PM – Tune up service…..399
TROUBLESHOOTING…..403
POINTS TO REMEMBER WHEN TROUBLESHOOTING…..404
SEQUENCE OF EVENTS IN TROUBLESHOOTING…..405
POINTS TO REMEMBER WHEN CARRYING OUT MAINTENANCE…..406
CHECKS BEFORE TROUBLESHOOTING…..414
CLASSIFICATION AND STEPS FOR TROUBLESHOOTING…..415
Failure-looking Phenomenon and Troubleshooting No…..416
How to read electric wire code…..419
CONNECTOR LOCATION CHART AND ELECTRICAL CIRCUIT DIAGRAM BY SYSTEM…..422
CONNECTOR LOCATIONS…..430
CONNECTION TABLE FOR CONNECTOR PIN NUMBERS…..451
TROUBLESHOOTING WHEN FAILURE CODE IS INDICATED…..485
Before carrying out troubleshooting when failure code is displayed…..487
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…..488
Relative Electrical Circuit Diagram…..489
Failure code [CA111] EMC Critical Internal Failure…..490
Failure code [CA115] Engine Neutral and Backup Speed Sensor Error…..491
Failure code [CA122] Chg Air Press Sensor High Error…..492
Failure code [CA123] Chg Air Press Sensor Low Error…..494
Failure code [CA131] Throttle Sensor High Error…..496
Failure code [CA132] Throttle Sensor Low Error…..498
Failure code [CA144] Coolant Temp Sens High Error…..500
Failure code [CA145] Coolant Temp Sens Low Error…..502
Failure code [CA153] Chg Air Temp Sensor High Error…..504
Failure code [CA154] Chg Air Temp Sensor Low Error…..506
Failure code [CA155] Chg Air Temp High Speed Derate…..508
Failure code [CA187] Sens Supply 2 Volt Low Error…..510
Failure code [CA221] Ambient Press Sens High Error…..512
Failure code [CA222] Ambient Press Sens Low Error…..514
Failure code [CA227] Sens Supply 2 Volt High Error…..516
Failure code [CA238] Ne Speed Sens Supply Volt Error…..518
Failure code [CA271] IMV/PCV1 Short Error…..520
Failure code [CA272] IMV/PCV1 Open Error…..522
Failure code [CA322] Inj #1 (L#1) Open/Short Error…..524
Failure code [CA324] Inj #3 (L#3) Open/Short Error…..527
Failure code [CA331] Inj #2 (L#2) Open/Short Error…..530
Failure code [CA332] Inj #4 (L#4) Open/Short Error…..533
Failure code [CA342] Calibration Code Incompatibility…..536
Failure code [CA351] Injectors Drive Circuit Error…..537
Failure code [CA352] Sensor Supply 1 Volt Low Error…..540
Failure code [CA386] Sens Supply 1 Volt High Error…..542
Failure code [CA428] Water in Fuel Sensor High Error…..544
Failure code [CA429] Water in Fuel Sensor Low Error…..546
Failure code [CA435] Eng Oil Press Sw Error…..548
Failure code [CA441] Battery Voltage Low Error…..550
Failure code [CA442] Battery Voltage High Error…..553
Failure code [CA449] Rail Press Very High Error…..555
Failure code [CA451] Rail Press Sensor High Error…..556
Failure code [CA452] Rail Press Sensor Low Error…..558
Failure code [CA488] Chg Air Temp High Torque Derate…..560
Failure code [CA553] Rail Press High Error…..561
Failure code [CA559] Rail Press Low Error…..562
Failure code [CA689] Eng Ne Speed Sensor Error…..564
Failure code [CA731] Eng Bkup Speed Sens Phase Error…..567
Failure code [CA757] All Continuous Data Lost Error…..568
Failure code [CA778] Eng G Speed Sensor Error…..570
Failure code [CA1633] KOMNET Datalink Timeout Error…..574
Failure code [CA2185] Throttle Sensor Supply Voltage High Error…..576
Failure code [CA2186] Throttle Sensor Supply Voltage Low Error…..578
Failure code [CA2249] Rail Press Very Low Error…..580
Failure code [CA2311] IMV Solenoid Error…..582
Failure code [CA2555] Grid Htr Relay Volt High Error…..584
Failure code [CA2556] Grid Heater Relay Volt Low Error…..586
Failure Code [D110KB] (Short-circuiting in battery relay)…..588
Failure code [D862KA] GPS Antenna Disconnection…..590
Configuration diagram of KOMTRAX system…..590
Failure Code [DA22KK] (Abnormality in pump pressure sensor)…..592
Failure code [DA25KP] Press. Sensor Power Abnormality…..594
Failure code [DA2RMC] Pump Comm. Abnormality…..596
Failure Code [DA2SKQ] (Abnormality in inputting model code)…..598
Failure Code [DA2SKQ] (Abnormality in inputting model code)…..600
Failure code [DAFRMC] Monitor Comm. Abnormality…..602
Failure code [DDC3KZ] Outrigger Switch Select Abnormality…..604
Failure Code [DDP4KX] (Abnormality in travel PPC pressure switch)…..606
Failure Code [DDWCKZ] (Abnormality in travel direction control switch)…..608
Failure code [DFB1KZ] Service Lever Potentio 1 Abnormality…..610
Failure code [DFB2KZ] Service Lever Potentio 2 Abnormality…..613
Failure code [DFB3L8] Service Lever 1 Potentio Error…..616
Failure code [DFB4L8] Service Lever 2 Potentio Error…..617
Failure code [DGH2KB] Hydr Oil Sensor Short…..619
Failure Code [DH1OKS] (Abnormality in Pressure sensor power source)…..620
Failure code [DHPAMA] F Pump Press Sensor Abnormality…..622
Failure Code [DHS5KX] (Abnormality in travel PPC sensor)…..624
Failure Code [DHX1MA] (Abnormality in overload caution sensor)…..626
Failure Code [DLT4KA] (Disconnection in transmission speed sensor in pump controller system)…..628
Failure Code [DW27KA] (Disconnection in Transmission Clutch solenoid)…..630
Failure Code [DW27KB] (Short-circuiting in Transmission Clutch solenoid)…..632
Failure Code DW4AKA (Disconnection in suspension lock solenoid)…..634
Failure Code [DW4AKB] (Short circuiting in suspension lock solenoid)…..636
Failure Code [DW4CKA] (Disconnection in PPC lock solenoid)…..638
Failure code [DW4CKB] PPC Lock Sol. S/C…..640
Failure Code [DW4MKA] (Disconnection in Creep solenoid)…..642
Failure Code [DW4MKB] (Short-circuiting in Creep solenoid)…..644
Failure Code [DW44KA] (Disconnection of Travel F/R solenoid)…..646
Failure Code [DW44KB] (Short-circuiting of Travel F/R solenoid)…..648
Failure Code [DW45KA] (Disconnection in Swing Parking Brake solenoid)…..650
Failure code [DW45KB] Swing Brake Sol. S/C…..654
Failure Code [DW91KA] (Disconnection in Travel Neutral solenoid)…..656
Failure Code [DW91KB] (Short-circuiting in Travel Neutral Solenoid)…..658
Failure Code [DWK0KA] (Disconnection in 2-stage Relief solenoid)…..660
Failure Code [DWK0KB] (Short-circuiting in 2-Stage Relief Solenoid)…..662
Failure Code [DWK2KA] (Disconnection in 2-stage Back Pressure solenoid)…..664
Failure Code [DWK2KB] (Short circuiting in 2-stage back pressure solenoid)…..666
Failure Code [DXA0KA] (Disconnection in PC-EPC solenoid system)…..668
Failure Code [DXA0KB] (Short-circuiting in PC-EPC solenoid)…..670
Failure Code [DXE0KA] (Disconnection in LS-EPC solenoid system)…..672
Failure Code [DXE0KB] (Short-circuiting in LS-EPC solenoid)…..674
Failure code [DXE4KA] Service Current EPC1 Discon…..676
Failure code [DXE4KB] Service Current EPC1 Short…..678
Failure code [DXE7KA] Service Current EPC2 Discon…..680
Failure code [DXE7KB] Service Current EPC2 Short…..682
Failure code [DXE8KA] Service Current EPC3 Discon…..684
Failure code [DXE8KB] Service Current EPC3 Short…..686
Failure code [DXE9KA] Service Current EPC4 Discon…..688
Failure code [DXE9KB] Service Current EPC4 Short…..690
Failure code [DY20KA] Wiper Working Abnormality…..692
Failure code [DY20MA] Wiper Parking Abnormality…..694
Failure code [DY2CKB] Washer Drive S/C…..696
Failure code [DY2DKB] Wiper Drive (For) S/C…..698
Failure code [DY2EKB] Wiper Drive (Rev) S/C…..700
TROUBLESHOOTING OF ELECTRICAL SYSTEM (E-MODE)…..703
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…..704
E-1 Engine does not start (Engine does not rotate)…..706
E-5 Auto-decelerator does not work…..711
E-6 Auto engine warm-up device does not work…..713
E-7 Preheater does not operate…..714
E-8 All work equipment, swing and travel do not move…..716
E-9 One-touch Power Max Switch does not work…..718
E-10 No display in monitor panel at all…..719
E-11 Part of display on monitor panel is missing…..720
E-12 Monitor panel displays contents irrelevant to the model…..720
E-13 Fuel level monitor red lamp lights up while engine is running…..721
E-14 Engine coolant temperature gauge does not indicate normally…..722
E-15 Hydraulic oil temperature gauge does not display correctly…..724
E-16 Fuel gauge does not display correctly…..725
E-17 Swing lock monitor does not display correctly…..726
E-18 When the monitor switch is operated, no display appears…..728
E-19 Windshield wiper and window washer do not operate…..729
E-20 Alarm buzzer cannot be stopped…..731
E-21 "Boom/Stabiliser RAISE" is not correctly displayed in monitor function…..732
E-22 "Boom/Stabiliser LOWER" is not correctly displayed in monitor function…..733
E-23 "Arm DIGGING" is not correctly displayed in monitor function…..734
E-24 "Arm DUMPING" is not correctly displayed in monitor function…..735
E-25 "Bucket DIGGING" is not correctly displayed in monitor function…..736
E-26 "Bucket DUMPING" is not correctly displayed in monitor function…..737
E-27 "SWING" is not correctly displayed in monitor function…..738
E-28 "TRAVEL" is not correctly displayed in monitor function…..740
E-29 "2 Piece Boom" is not correctly displayed in monitor function…..742
E-30 Air Conditioner does not work…..744
E-31 Travel reverse alarm does not sound…..746
E-32 KOMTRAX system does not operate normally…..748
TROUBLESHOOTING OF ELECTRICAL SYSTEM (Error checking of items without Monitor codes)…..751
Relative Electrical Circuit Diagram…..753
Radio Cassette & Telephone Socket…..754
Electrical Circuit Diagram For Radio Cassette & Telephone Socket…..755
PPC Lock Circuit…..756
Circuit Diagram for PPC Lock Circuit…..757
Brake Light Circuit…..758
Circuit Diagram for Brake Light Circuit…..759
Undercarriage Attachments – Mode Selection…..760
Circuit Diagram for Undercarriage Attachments – Mode Selection…..761
Undercarriage Attachments – Front Left Outrigger…..762
Circuit Diagram for Undercarriage Attachments – Front Left Outrigger…..763
Undercarriage Attachments – Front Right Outrigger…..764
Circuit Diagram for Undercarriage Attachments – Front Right Outrigger…..765
Undercarriage Attachments – Rear Left Outrigger…..766
Undercarriage Attachments – Rear Right Outrigger…..768
Circuit Diagram for Undercarriage Attachments – Rear Right Outrigger…..769
Heated Seat Does Not Warm Up…..770
Circuit Diagram for the Heated Seat…..771
Suspension Lock…..772
Circuit Diagram for Suspension Lock…..773
Lower Wiper Does Not Work (Optional Fitment)…..774
Circuit Diagram for Lower Wiper…..775
Work Lights (Operator Cab Front Left)…..776
Work Lights (Operator Cab Front Right)…..777
Work Lights (Operator Cab Rear)…..778
Circuit Diagram for Work Lights…..779
Worklights (Boom, Arm & Counterweight)…..780
Circuit Diagram for Worklights (Boom & Counterweight)…..781
Cab and Counterweight Beacon Light…..782
Circuit Diagram for Cab & Counterweight Beacon Light…..783
Air Seat Compressor (Option – Air Suspension Seat)…..784
Circuit Diagram for Air Seat Compressor (Option – Air Suspension Seat)…..785
Operator Cab Interior Light…..786
Circuit Diagram for Operator Cab Interior Light…..787
Cigar Lighter…..788
Circuit Diagram for Cigar Lighter…..789
Park Brake (Not Activating)…..790
Circuit Diagram for Park Brake…..791
Park Brake (Displayed Symbol)…..792
Circuit Diagram for Park Brake…..793
RH PPC Lever Clamshell Roller Switch Pushed to the LH Position…..794
Circuit Diagram for Clamshell Control…..795
RH PPC Lever Clamshell Roller Switch Pushed to the RH Position…..796
Circuit Diagram for Clamshell Control…..797
RH PPC Lever Clamshell Roller Switched Pushed to the RH or LH…..798
Circuit Diagram for Clamshell Control…..799
Horns…..800
Circuit Diagram for Horn…..801
Swing Lock – Normal Operation…..802
Circuit Diagram for Swing Lock…..803
Swing Lock – Emergency Operation…..804
Circuit Diagram for Swing Lock – Emergency Operation…..805
Neutral Start (Engine)…..806
Neutral Start (Engine) contd (A)…..807
Neutral Start (Engine) contd (B)…..808
Neutral Start (Engine) contd (C)…..809
Circuit Diagram for Neutral Start (Engine)…..810
Emergency Travel Control – Forward…..811
Circuit Diagram for Travel Direction Control…..812
Emergency Travel Control – Neutral…..813
Circuit Diagram for Travel Direction Control…..814
Emergency Travel Control – Reverse…..815
Emergency Travel Control – Reverse contd…..816
Circuit Diagram for Travel Direction Control…..817
Driving Lights – Main Beam…..818
Circuit Diagram for Driving Lights…..819
Driving Lights – Main Beam Flash…..820
Circuit Diagram for Driving Lights…..821
Driving Lights – Main Beam Dipped…..822
Circuit Diagram for Driving Lights…..823
Driving Lights – Position Lights…..824
Circuit Diagram for Driving Lights…..825
Driving Lights – Position Lights contd (1) and (2)…..826
Circuit Diagram for Driving Lights…..827
Indicators – Right Hand…..828
Circuit Diagram for Indicators & Hazard Warning…..829
Indicators – Left Hand…..830
Circuit Diagram for Indicators & Hazard Warning…..831
Hazard Warning Lights…..832
Circuit Diagram for Indicators & Hazard Warning…..833
Hazard Warning Lights contd (A)…..834
Circuit Diagram for Indicators & Hazard Warning…..835
Swing Lock Proximity Switch…..836
Brake and Swing Lock Proximity Switches…..837
TROUBLESHOOTING OF HYDRAULIC AND MECHANICAL SYSTEM (H-MODE)…..839
SYSTEM CHART FOR HYDRAULIC AND MECHANICAL SYSTEMS…..840
INFORMATION CONTAINED IN TROUBLESHOOTING TABLE…..844
Quick coupler…..863
30 DISASSEMBLY AND ASSEMBLY…..865
HOW TO READ THIS MANUAL…..869
REMOVAL AND INSTALLATION OF ASSEMBLIES…..869
DisassemblY and assemblY OF assemblIES…..870
SPECIAL TOOLS…..875
SKETCHES…..875
LIST OF TOOLS…..876
PRECAUTIONS WHEN PERFORMING OPERATION…..880
STARTING MOTOR ASSEMBLY…..882
FUEL Supply PUMP assembly…..883
FUEL INJECTOR ASSEMBLY…..886
FRONT OIL SEAL…..891
REAR OIL SEAL…..893
CYLINDER HEAD ASSEMBLY…..896
COMBINATION COOLER…..906
FUEL COOLER ASSEMBLY…..909
ENGINE AND HYDRAULIC PUMP ASSEMBLIES…..910
TRAVEL MOTOR ASSEMBLY…..917
TRAVEL MOTOR ASSEMBLY…..919
SWING MOTOR AND SWING MACHINERY ASSEMBLY…..923
SWING MACHINERY ASSEMBLY…..924
SWING MOTOR ASSEMBLY…..932
FRONT AXLE ASSEMBLY…..941
FRONT AXLE ASSEMBLY…..943
REAR AXLE AND TRANSMISSION ASSEMBLY…..992
REAR AXLE ASSEMBLY…..995
TRANSMISSION ASSEMBLY…..1025
PROPSHAFT ASSEMBLY…..1054
WHEEL ASSEMBLY…..1056
SUSPENSION LOCK CYLINDER ASSEMBLY…..1057
SUSPENSION LOCK CYLINDERS ASSEMBLY…..1058
OUTRIGGER ASSEMBLY…..1059
OUTRIGGER ASSEMBLY…..1060
DOZER BLADE…..1061
DOZER BLADE ASSEMBLY…..1062
SWING CIRCLE ASSEMBLY…..1063
REVOLVING FRAME ASSEMBLY…..1064
CENTRE SWIVEL JOINT ASSEMBLY…..1067
CENTRE SWIVEL JOINT ASSEMBLY…..1070
HYDRAULIC TANK ASSEMBLY…..1072
FUEL TANK ASSEMBLY…..1076
CONTROL VALVE ASSEMBLY…..1078
LS SEPARATION VALVE ASSEMBLY…..1082
PRESSURE COMPENSATION VALVE ASSEMBLY…..1083
MAIN RELIEF VALVE ASSEMBLY…..1084
LS CONTROL EPC VALVE ASSEMBLY…..1085
EPC SOLENOID VALVE ASSEMBLY…..1086
4 STATION PPC SOLENOID VALVE BLOCK ASSEMBLY…..1087
MANIFOLD BLOCK ASSEMBLY…..1089
OIL SEAL IN HYDRAULIC PUMP INPUT SHAFT…..1090
WORK EQUIPMENT PPC VALVE ASSEMBLY…..1091
HYDRAULIC CYLINDER ASSEMBLY…..1092
MONOBOOM WORK EQUIPMENT ASSEMBLY…..1098
2 PIECE BOOM WORK EQUIPMENT ASSEMBLY…..1101
AIR CONDITIONER UNIT ASSEMBLY…..1104
COUNTERWEIGHT ASSEMBLY…..1108
OPERATOR CAB ASSEMBLY…..1110
MONITOR ASSEMBLY…..1113
GOVERNOR / PUMP CONTROLLER ASSEMBLY…..1114
KOMTRAX TERMINAL…..1115
ENGINE CONTROLLER…..1116
90 OTHERS…..1117
Mono boom…..1118
Two plece boom…..1119
Hydraulic circuit diagram 1/3…..1121
Hydraulic circuit diagram 2/3…..1123
Hydraulic circuit diagram 3/3…..1125
Electrical circuit diagram 1/7…..1127
Electrical circuit diagram 2/7…..1129
Electrical circuit diagram 3/7…..1131
Electrical circuit diagram 4/7…..1133
Electrical circuit diagram 5/7…..1135
Electrical circuit diagram 6/7…..1137
Electrical circuit diagram 7/7…..1139

Komatsu Wheeled Excavator PW160-7E0 Repair Service Manuals


INSTANT DOWNLOAD


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Komatsu Wheeled Excavator PW150 Repair Service Manuals


INSTANT DOWNLOAD


Complete service repair manual with Electrical Wiring Diagrams for Komatsu Wheeled Excavator PW150-1, with all the technical information to maintain, diagnose, repair, and rebuild like professional mechanics.

Komatsu Wheeled Excavator PW150-1 workshop service repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

SEBM020E0104 – Wheeled Excavator PW150-1 Shop Manual.pdf
UEAM000106 – Wheeled Excavator PW150ES-6K Operation & Maintenance Manual.pdf

PRODUCT DETAILS:
Total Pages: 790 pages
File Format: PDF
Language: English

MAIN SECTIONS
SEBM020E0104 – Wheeled Excavator PW150-1 Shop Manual…..2
COVER…..2
CONTENTS…..3
01 GENERAL…..36
GENERAL VIEW…..37
GENERAL ASSEMBLY DRAWING…..38
SPECIFICATIONS…..39
ENGINE ASSEMBLY DRAWING…..41
ENGINE SPECIFICATIONS…..42
WEIGHT TABLE…..43
TABLE OF OIL AND COOLANT CAPACITIES…..44
10 ENGINE …..45
11 STRUCTURE AND FUNCTION…..45
ENGINE MOUNT…..46
RADIATOR AND HYDRAULIC OIL COOLER …..47
PTO (POWER TAKE-OFF)…..48
FUEL TANK AND PIPING…..49
ENGINE CONTROL…..50
12 TESTING AND ADJUSTING…..51
STANDARDS FOR TESTING AND ADJUSTING…..52
TOOLS FOR TESTING AND ADJUSTING…..53
ADJUSTING VALVE CLEARANCE…..54
TESTING AND ADJUSTING FAN BELT TENSION…..55
TESTING AND ADJUSTING FUEL INJECTION TIMING…..56
MEASURING BLOW-BY…..58
MEASURING COMPRESSION PRESSURE…..59
LUBRICATION SYSTEM…..60
MEASURING EXHAUST GAS COLOR…..61
MEASURING COOLANT TEMPERATURE…..62
13 DISASSEMBLY AND ASSEMBLY…..63
STARTING MOTOR…..64
DISMOUNTING…..64
MOUNTING…..64
ALTERNATOR…..65
DISMOUNTING…..65
MOUNTING…..65
ENGINE OIL COOLER…..66
DISMOUNTING…..66
MOUNTING…..66
NOZZLE HOLDER…..67
DISMOUNTING…..67
MOUNTING…..67
FUEL INJECTION PUMP…..68
DISMOUNTING…..68
MOUNTING…..70
AIR COMPRESSOR…..72
DISMOUNTING…..72
MOUNTING…..73
WATER PUMP…..74
DISMOUNTING…..74
MOUNTING…..76
CYLINDER HEAD…..78
DISMOUNTING…..78
MOUNTING…..84
RADIATOR AND HYDRAULIC OIL COOLER…..91
DISMOUNTING…..91
MOUNTING…..94
ENGINE …..97
DISMOUNTING…..97
MOUNTING…..102
PTO…..107
DISMOUNTING…..107
MOUNTING…..107
20 POWER TRAIN…..108
21 STRUCTURE AND FUNCTION…..108
POWER TRAIN…..109
1. OUTLINE…..109
2. SCHEMATIC OF POWER TRAIN…..110
3. HYDRAULIC CIRCUIT DIAGRAM…..111
TRAVEL SYSTEM…..113
1. OUTLINE…..113
2. SCHEMATIC OF TRAVEL SYSTEM…..114
3. HYDRAULIC CIRCUIT DIAGRAM…..115
4. CENTER SWIVEL JOINT…..117
5. TRAVEL MOTOR AND BRAKE VALVE…..118
6. TRAVEL SHUTTLE VALVE…..127
7. TRAVEL SUCTION VALVE…..129
8. TRANSMISSION…..130
9. TRAVEL CONTROL SYSTEM…..134
SWING SYSTEM…..142
1. OUTLINE…..142
2. SCHEMATIC OF SWING SYSTEM…..143
3. HYDRAULIC CIRCUIT DIAGRAM…..144
4. SWING MOTOR AND BRAKE VALVE…..145
5. SWING MACHINERY…..152
6. SWING CIRCLE…..153
23 DISASSEMBLY AND ASSEMBLY…..154
CENTER SWIVEL JOINT…..155
DISMOUNTING…..155
MOUNTING…..157
DISASSEMBLY…..159
ASSEMBLY…..160
TRAVEL MOTOR…..161
DISMOUNTING…..161
MOUNTING…..162
DISASSEMBLY…..163
ASSEMBLY…..167
TRAVEL BRAKE VALVE…..174
DISMOUNTING…..174
MOUNTING…..174
TRANSMISSION…..175
DISMOUNTING…..175
MOUNTING…..178
DISASSEMBLY…..181
ASSEMBLY…..187
SWING MOTOR AND BRAKE VALVE…..193
DISMOUNTING…..193
MOUNTING…..193
SWING MACHINERY…..194
DISMOUNTING…..194
MOUNTING…..194
DISASSEMBLY…..195
ASSEMBLY…..198
SWING CIRCLE…..202
DISMOUNTING…..202
MOUNTING…..205
24 MAINTENANCE STANDARD…..208
CENTER SWIVEL JOINT…..209
TRAVEL BRAKE VALVE…..210
TRAVEL SHUTTLE VALVE…..212
TRAVEL SUCTION VALVE…..213
TRANSMISSION…..214
SWING MACHINERY…..215
SWING CIRCLE…..216
40 STEERING SYSTEM…..217
41 STRUCTURE AND FUNCTION…..217
STEERING SYSTEM…..218
1. OUTLINE…..218
2. SCHEMATIC OF STEERING SYSTEM…..219
3. HYDRAULIC CIRCUIT DIAGRAM…..220
4. STEERING PUMP…..221
5. STEERING MAIN RELIEF VALVE…..222
6. STEERING VALVE…..223
7. STEERING CYLINDER…..232
8. AXLE…..233
9. DRIVE SHAFT…..237
10.WHEEL…..238
BRAKE SYSTEM…..239
1. OUTLINE…..239
2. SCHEMATIC OF BRAKE SYSTEM…..240
3. PNEUMATIC CIRCUIT DIAGRAM…..241
4. BRAKE VALVE…..242
5. SHUTTLE VALVE (DOUBLE CHECK VALVE)…..244
6. AIR MASTER…..245
7. WHEEL BRAKE…..247
8. PARKING BRAKE…..248
9. PARKING BRAKE CHAMBER…..249
10. 2-WAY CONTROL VALVE…..251
11. QUICK-RELEASE VALVE…..253
SUSPENSION SYSTEM…..254
1. OUTLINE…..254
2. SCHEMATIC OF SUSPENSION SYSTEM…..255
3. HYDRAULIC AND PNEUMATIC CIRCUIT DIAGRAM…..256
4. SUSPENSION LOCK VALVE…..257
5. SUSPENSION LOCK CYLINDER…..259
42 TESTING AND ADJUSTING…..260
TESTING AND ADJUSTING TOE-IN…..261
ADJUSTING MAXIMUM TURNING ANGLE OF FRONT WHEELS…..262
ADJUSTING PARKING BRAKE…..264
ADJUSTING PARKING BRAKE ROD…..265
BLEEDING AIR FROM BRAKE CIRCUIT…..266
43 DISASSEMBLY AND ASSEMBLY…..267
STEERING PUMP…..268
DISMOUNTING…..268
MOUNTING…..268
STEERING MAIN RELIEF VALVE…..269
DISASSEMBLY…..269
ASSEMBLY…..269
STEERING CYLINDER…..270
DISMOUNTING…..270
MOUNTING…..270
REAR AXLE…..271
DISMOUNTING…..271
MOUNTING…..271
FRONT AXLE…..272
DISMOUNTING…..272
MOUNTING…..273
DISASSEMBLY…..274
ASSEMBLY…..278
DIFFERENTIAL (FRONT)…..283
DISMOUNTING…..283
MOUNTING…..283
DIFFERENTIAL (REAR)…..284
DISMOUNTING…..284
MOUNTING…..285
DISASSEMBLY…..286
ASSEMBLY…..288
AIR MASTER ASSEMBLY…..293
DISMOUNTING…..293
MOUNTING…..293
DISC PLATE (REAR)…..294
DISMOUNTING…..294
MOUNTING…..298
REAR CALIPER…..302
DISMOUNTING…..302
MOUNTING…..302
FRONT CALIPER…..303
DISMOUNTING…..303
MOUNTING…..303
DISASSEMBLY…..304
ASSEMBLY…..304
PARKING BRAKE…..305
DISMOUNTING…..305
MOUNTING…..305
SUSPENSION LOCK VALVE…..306
DISMOUNTING…..306
MOUNTING…..306
SUSPENSION LOCK CYLINDER…..307
DISMOUNTING…..307
MOUNTING…..307
DISASSEMBLY…..308
ASSEMBLY…..308
44 MAINTENANCE STANDARD…..309
STEERING PUMP…..310
STEERING CYLINDER…..311
FINAL DRIVE AND DIFFERENTIAL…..312
KING PIN AND KNUCKLE AND TIE-ROD…..314
WHEEL BRAKE…..315
PARKING BRAKE…..316
SUSPENSION LOCK CYLINDER…..317
50 AIR SYSTEM…..318
51 STRUCTURE AND FUNCTION…..318
AIR SYSTEM…..319
1. OUTLINE…..319
2. SCHEMATIC OF AIR SYSTEM…..321
3. PNEUMATIC CIRCUIT DIAGRAM…..323
4. AIR GOVERNOR…..324
5. PARKING LAMP SWITCH…..326
6. LOW PRESSURE INDICATOR SWITCH…..327
7. PRESSURE REGULATOR VALVE…..328
8. STOP LAMP SWITCH…..330
60 HYDRAULIC SYSTEM…..331
61 STRUCTURE AND FUNCTION…..331
HYDRAULIC SYSTEM…..332
1. OUTLINE…..332
2. SCHEMATIC OF HYDRAULIC SYSTEM…..334
3. HYDRAULIC CIRCUIT DIAGRAM…..336
4. HYDRAULIC TANK AND FUEL TANK…..340
5. HYDRAULIC PUMP…..341
6. CONTROL VALVE…..354
WORK EQUIPMENT HYDRAULIC SYSTEM…..369
BOOM, ARM AND BUCKET…..369
1. OUTLINE…..369
2. SCHEMATIC OF WORK EQUIPMENT SYSTEM…..370
3. HYDRAULIC CIRCUIT DIAGRAM…..372
4. SLOW RETURN VALVE…..374
5. HYDRAULIC CYLINDER…..377
OUTRIGGER…..380
1. OUTLINE…..380
2. SCHEMATIC OF OUTRIGGER SYSTEM…..381
3. HYDRAULIC CIRCUIT DIAGRAM…..382
4. DOUBLE CHECK VALVE…..383
5. HYDRAULIC CYLINDER…..384
LEFT AND RIGHT INDEPENDENT OUTRIGGERS…..385
1. OUTLINE…..385
2. SCHEMATIC OF LEFT AND RIGHT INDEPENDENT OUTRIGGERS…..386
3. HYDRAULIC AND AIR CIRCUIT DIAGRAM…..387
4. AIR DIRECTION SELECTOR VALVE…..388
5. HYDRAULIC DIRECTION SELECTOR VALVE…..389
FRONT OUTRIGGER AND REAR EQUIPMENT…..392
1. OUTLINE…..392
2. SCHEMATIC OF FRONT OUTRIGGER AND REAR EQUIPMENT…..393
3. HYDRAULIC AND AIR CIRCUIT DIAGRAM…..394
4. AIR DIRECTION SELECTOR VALVE…..395
5. HYDRAULIC DIRECTION SELECTOR VALVE…..396
DOZER BLADE (IF EQUIPPED)…..398
1. OUTLINE…..398
2. SCHEMATIC OF DOZER BLADE…..399
3. HYDRAULIC CIRCUIT DIAGRAM…..400
4. HYDRAULIC CYLINDER…..401
PPC CONTROL SYSTEM…..402
1. OUTLINE…..402
2. SCHEMATIC OF PPC CONTROL SYSTEM…..403
3. PPC VALVE…..409
4. R.H. PPC SHUTTLE VALVE…..414
5. SOLENOID VALVE…..415
62 TESTING AND ADJUSTING…..417
STANDARD FOR TESTING AND ADJUSTING…..418
TESTING TRAVEL OF CONTROL LEVERS…..423
TESTING OPERATING FORCE OF CONTROL LEVERS…..423
MEASURING OIL TEMPERATURE…..424
MEASURING LEAKAGE OF SWING AND TRAVEL MOTOR…..425
MEASURING HYDRAULIC DRIFT OF WORK EQUIPMENT…..426
BLEEDING AIR…..427
MEASURING PLACE OF OIL PRESSURE…..428
ADJUSTING PLACE OF HYDRAULIC PRESSURE…..428
TESTING AND ADJUSTING MAIN RELIEF VALVE…..429
CHECKING HYDRAULIC ASSIST SYSTEM…..432
TROUBLESHOOTING…..433
1. FORWARD-REVERSE SELECTOR IS INOPERATED…..434
2. WORK EQUIPMENT SPEED IS SLOW, OR THERE IS NO POWER…..436
3. MACHINE SPEED IS SLOW…..438
4. SWING SPEED IS SLOW…..440
5. ENGINE STALLS OR SPEED DROPS EXCESSIVELY DURING OPERATIONS…..442
6. UPPER STRUCTURE DOES NOT SWING…..444
63 DISASSEMBLY AND ASSEMBLY…..446
HYDRAULIC PUMP…..447
DISMOUNTING…..447
MOUNTING…..447
SERVO VALVE…..448
DISMOUNTING…..448
MOUNTING…..448
L .H . 7-SPOOL CONTROL VALVE…..449
DISMOUNTING…..449
MOUNTING…..450
DISASSEMBLY…..451
ASSEMBLY…..453
R .H . 5-SPOOL CONTROL VALVE…..455
DISMOUNTING…..455
MOUNTING…..456
SAFETY VALVE AND SUCTION VALVE…..457
DISASSEMBLY…..457
ASSEMBLY…..458
MAIN RELIEF VALVE…..459
DISASSEMBLY…..459
ASSEMBLY…..459
SLOW RETURN VALVE…..460
DISMOUNTING…..460
MOUNTING…..460
DISASSEMBLY…..461
ASSEMBLY…..461
BOOM CYLINDER…..462
DISMOUNTING…..462
MOUNTING…..463
ARM CYLINDER…..464
DISMOUNTING…..464
MOUNTING…..464
BUCKET CYLINDER…..465
DISMOUNTING…..465
MOUNTING…..465
OUTRIGGER CYLINDER…..466
DISMOUNTING…..466
MOUNTING…..467
HYDRAULIC CYLINDER…..468
DISASSEMBLY…..468
ASSEMBLY…..470
HYDRAULIC CYLINDER PISTON RING AND WEAR RING…..473
DISMOUNTING…..473
MOUNTING…..473
64 MAINTENANCE STANDARD…..474
L .H . 7-SPOOL CONTROL VALVE…..475
R .H . 5-SPOOL CONTROL VALVE…..479
CONTROL PUMP…..483
SLOW RETURN VALVE…..484
HYDRAULIC CYLINDER…..485
70 WORK EQUIPMENT…..487
71 STRUCTURE AND FUNCTION…..487
WORK EQUIPMENT …..488
1. BOOM, ARM AND BUCKET…..488
2. REAR OUTRIGGER…..489
3. FRONT OUTRIGGER (IF EQUIPPED)…..490
4. DOZER BLADE IF (IF EQUIPPED)…..491
73 DISASSEMBLY AND ASSEMBLY…..492
OPERATOR'S CAB…..493
DISMOUNTING…..493
MOUNTING…..494
WORK EQUIPMENT…..495
DISMOUNTING…..495
MOUNTING…..496
DISASSEMBLY…..497
ASSEMBLY…..501
74 MAINTENANCE STANDARD…..504
WORK EQUIPMENT…..505
80 ELECTRIC AND ELECTRONIC SYSTEM…..507
81 STRUCTURE AND FUNCTION…..507
ELECTRIC AND ELECTRONIC SYSTEM…..508
1. OUTLINE…..508
2. ELECTRIC CIRCUIT DIAGRAM…..510
90 OTHERS…..512
91 OTHERS…..512
OPERATOR'S CAB HEATER…..513
OVERLOAD WARNING DEVICE (IF EQUIPPED)…..514
UEAM000106 – Wheeled Excavator PW150ES-6K Operation & Maintenance Manual…..518
FOREWORD…..520
FOREWORD…..521
SAFETY INFORMATION…..523
SAFETY MESSAGES…..523
NOISE…..524
VIBRATION…..524
EMERGENCY STEERING…..525
INTRODUCTION…..526
INTENDED USE…..526
FEATURES…..526
BREAKING IN YOUR NEW MACHINE…..526
LOCATIONS OF PLATES, TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..528
MACHINE SERIAL NO. PLATE POSITION…..528
ENGINE SERIAL NO. PLATE POSITION…..528
TABLE TO ENTER SERIAL NO. AND DISTRIBUTOR…..528
MACHINE SERIAL PLATES…..529
STANDARD SERIAL PLATE…..529
GERMANY SERIAL PLATE…..529
ITALIAN SERIAL PLATE…..529
STANDARD SERIAL PLATE…..530
GERMANY SERIAL PLATE…..530
SAFETY…..536
GENERAL PRECAUTIONS…..537
PRECAUTION DURING OPERATION…..543
BEFORE STARTING ENGINE…..543
OPERATING MACHINE…..544
TRANSPORTATION…..549
BATTERY…..550
TOWING…..551
BUCKET WITH HOOK OR BUCKET LINK…..552
GENERAL PRECAUTIONS…..552
PRECAUTIONS FOR LIFTING OPERATION…..554
PRECAUTIONS FOR MAINTENANCE…..556
BEFORE CARRYING OUT MAINTENANCE…..556
DURING MAINTENANCE…..559
POSITION FOR ATTACHING SAFETY LABELS…..562
POSITION FOR ATTACHING SAFETY LABELS…..562
OVERLOAD CAUTION…..577
OPERATION…..578
GENERAL VIEW…..579
GENERAL VIEW OF MACHINE…..579
GENERAL VIEW OF CONTROLS AND GAUGES…..580
EXPLANATION OF COMPONENTS…..582
MACHINE MONITOR…..582
A. BASIC CHECK ITEMS…..582
B. CAUTION ITEMS…..583
C. EMERGENCY STOP ITEMS…..583
D. METER DISPLAY PORTION…..583
E. SWITCHES…..583
A: BASIC CHECK ITEMS…..584
B: CAUTION ITEMS…..585
C: EMERGENCY STOP ITEMS…..586
D: METER DISPLAY PORTION…..587
E: SWITCHES…..590
SWITCHES…..593
CONTROL LEVERS, PEDALS…..603
CLEAR RAIN VISOR…..606
PULL DOWN SUN VISOR…..606
FRONT WINDOW…..607
DOOR LOCK…..610
CAP, COVER WITH LOCK…..611
METHOD OF OPENING AND CLOSING CAP WITH LOCK (For the fuel tank filler port)…..611
METHOD OF OPENING AND CLOSING COVER WITH LOCK (cover with Iock)…..611
FUSE…..612
LUGGAGE TRAY…..613
ASHTRAY…..613
CUP HOLDER…..613
HEATER…..614
VIEW OF CONTROL PANEL…..614
AIR CONDITIONER…..616
VIEW OF CONTROL PANEL…..616
PRECAUTION WHEN USING AIR CONDITIONER…..618
FUSIBLE LINK…..619
CONTROLLERS…..619
TOOL BOX…..619
REFUELLING PUMP…..619
CAB RADIO (OPTION)…..620
PRECAUTION OF USE…..620
WARNING LAMPS…..621
HANDLING THE ACCUMULATOR…..622
OPERATION…..623
CHECK BEFORE STARTING ENGINE…..623
WALK-AROUND CHECK…..623
CHECK BEFORE STARTING…..625
ADJUSTMENT BEFORE OPERATION OPERATORS SEAT…..629
OPERATIONS AND CHECKS BEFORE STARTING ENGINE…..630
STARTING ENGINE…..632
NORMAL STARTING…..632
STARTING IN COLD WEATHER…..633
OPERATIONS AND CHECKS AFTER STARTING ENGINE…..634
WHEN NORMAL…..634
IN COLD AREAS (AUTOMATIC WARMING-UP OPERATION)…..636
MOVING MACHINE OFF…..640
MOVING MACHINE FORWARD…..640
STEERING…..643
STOPPING…..644
STOPPING MACHINE (NORMAL)…..644
SWINGING (Slewing the upper carriage)…..645
OPERATION OF WORK EQUIPMENT…..646
WORKING MODE SELECTION…..647
PROHIBITIONS FOR OPERATION…..649
PRECAUTIONS FOR OPERATION…..650
PRECAUTIONS WHEN TRAVELING UP OR DOWN HILLS…..651
HOW TO ESCAPE FROM MUD…..652
WHEN ONE SIDE IS STUCK…..652
WHEN BOTH SIDES ARE STUCK…..653
WORK POSSIBLE USING HYDRAULIC EXCAVATOR…..653
BACKHOE WORK…..653
SHOVEL WORK…..653
DITCHING WORK…..654
LOADING WORK…..654
REPLACEMENT AND INVERSION OF BUCKET…..654
REPLACEMENT…..654
INVERSION…..655
PARKING MACHINE…..657
CHECK AFTER FINISHING WORK…..658
STOPPING ENGINE…..658
CHECK AFTER STOPPING ENGINE…..659
LOCKING…..659
OVERLOAD WARNING DEVICE…..659
HANDLING THE WHEELS…..660
TRANSPORTATION…..665
LOADING, UNLOADING WORK…..665
PRECAUTIONS FOR LOADING…..667
HOW TO LIFT THE MACHINE…..668
PRECAUTIONS FOR TRANSPORTATION…..669
TRAVELLING POSTURE…..670
COLD WEATHER OPERATION…..671
PRECAUTIONS FOR LOW TEMPERATURE…..671
FUEL AND LUBRICANTS…..671
COOLANT…..671
BATTERY…..672
PRECAUTIONS AFTER COMPLETION OF WORK…..672
AFTER COLD WEATHER…..673
LONG-TERM STORAGE…..674
BEFORE STORAGE…..674
DURING STORAGE…..674
AFTER STORAGE…..675
STARTING MACHINE AFTER LONG-TERM STORAGE…..675
TROUBLESHOOTING…..676
PHENOMENA THAT ARE NOT FAILURES…..676
METHOD OF TOWING MACHINE…..677
PRECAUTIONS ON PARTICULAR JOBSITES…..677
IF BATTERY IS DISCHARGED…..678
STARTING ENGINE WITH BOOSTER CABLE…..678
OTHER TROUBLE…..680
ELECTRICAL SYSTEM…..680
CHASSIS…..681
ENGINE…..682
ELECTRONIC CONTROL SYSTEM…..683
MAINTENANCE…..684
GUIDES TO MAINTENANCE…..685
OUTLINES OF SERVICE…..688
OUTLINE OF OIL, FUEL, COOLANT…..688
OIL…..688
FUEL…..689
COOLANT…..689
GREASE…..690
STORING OIL AND FUEL…..690
FILTERS…..690
OUTLINE OF ELECTRIC SYSTEM…..691
OUTLINE OF HYDRAULIC SYSTEM…..691
WEAR PARTS LIST…..693
USE FUEL, COOLANT AND LUBRICANTS ACCORDING TO AMBIENT TEMPERATURE…..694
PROPER SELECTION OF FUEL, COOLANT AND LUBRICANTS…..694
STANDARD TIGHTENING TORQUES FOR BOLTS AND NUTS…..698
INTRODUCTION OF NECESSARY TOOLS…..698
TORQUE LIST…..698
PERIODIC REPLACEMENT OF SAFETY CRITICAL PARTS…..700
SAFETY CRITICAL PARTS…..701
MAINTENANCE SCHEDULE CHART…..702
MAINTENANCE WHEN USING HYDRAULIC BREAKER…..707
USE OF BIO-DEGRADEABLE OIL…..707
Filter changes…..707
Oil changes…..707
SERVICE PROCEDURE…..708
INITIAL 250 HOURS SERVICE…..708
WHEN REQUIRED…..709
CHECK, CLEAN AND REPLACE THE AIR CLEANER ELEMENT…..709
CLEAN INSIDE OF COOLING SYSTEM…..710
CHECKING COOLANT LEVEL…..713
DRAINING THE SYSTEM…..713
CLEANING THE SYSTEM…..713
FILLING THE SYSTEM…..714
REFILLING AN OVERHEATED SYSTEM…..714
CLEANING THE RADIATOR…..715
CLEANING THE RADIATOR PRE-SCREEN…..715
THERMOSTATS…..715
FAN…..716
CHECK AND TIGHTEN WHEEL NUTS…..716
CHECK ELECTRICAL INTAKE AIR HEATER…..716
CHECK ALTERNATOR…..716
CHECK START MOTOR…..717
REPLACE BUCKET SIDE CUTTERS…..717
REPLACE BUCKET TEETH…..718
ADJUST BUCKET CLEARANCE…..719
CHECK WINDOW WASHER FLUID LEVEL, ADD FLUID…..719
CHECK AND ADJUST AIR CONDITIONER…..720
DRAIN ENGINE BREATHER OIL CATCHER…..721
CHECK BEFORE STARTING…..722
CHECK COOLANT LEVEL, ADD WATER…..722
CHECK OIL LEVEL IN ENGINE OIL PAN, ADD OIL…..722
CHECK FUEL LEVEL, ADD FUEL…..723
CHECK OIL LEVEL IN HYDRAULIC TANK, ADD OIL…..724
CHECK AIR CLEANER FOR CLOGGING…..724
CHECK ELECTRIC WIRING…..725
CHECK FOR WATER AND SEDIMENT IN SEDIMENTOR. DRAIN WATER AND SEDIMENT…..725
EVERY 50 HOURS…..726
DRAIN WATER AND SEDIMENT FROM FUEL TANK…..726
EVERY 100 HOURS SERVICE…..726
LUBRICATING…..726
CHECK OIL LEVEL IN SWING MACHINERY CASE, ADD OIL…..729
CLEAN FRESH AIR INTAKE FILTER…..730
EVERY 250 HOURS SERVICE…..731
CHECK OIL LEVEL IN WHEEL HUBS, ADD OIL…..731
CHECK OIL LEVEL IN AXLES, ADD OIL…..731
CHECK OIL LEVEL IN TRANSMISSION, ADD OIL…..732
CHECK LEVEL OF BATTERY ELECTROLYTE…..732
LUBRICATE SWING CIRCLE (2 points)…..733
BELTS, GENERAL…..733
CHECK FAN BELT TENSION, ADJUST CHECKING TENSION…..734
REPLACEMENT…..734
CHECK ALTERNATOR AND WATER PUMP BELT TENSION, ADJUST CHECKING TENSION…..734
CHECK AND ADJUST TENSION OF AIR CONDITIONER COMPRESSOR BELT…..735
EVERY 500 HOURS SERVICE…..736
REPLACE FUEL FILTER CARTRIDGE…..736
CHECK SWING PINION GREASE LEVEL, ADD GREASE…..738
CHANGE OIL IN ENGINE OIL PAN, REPLACE ENGINE OIL FILTER CARTRIDGE…..739
CLEAN AND INSPECT RADIATOR FINS, AFTER COOLER FINS, OIL COOLER FINS AND CONDENSER FINS (ONLY FOR ……740
REPLACE HYDRAULIC TANK BREATHER ELEMENT…..741
REPLACE HYDRAULIC FILTER ELEMENT…..741
EVERY 1000 HOURS SERVICE…..742
CHANGE OIL IN SWING MACHINERY CASE…..742
CHECK ALL TIGHTENING PARTS OF TURBOCHARGER…..743
CHECK PLAY OF TURBOCHARGER ROTOR…..743
CHECK & ADJUST VALVE CLEARANCE…..743
CHECK FAN BELT TENSIONER BEARING BELT AND FAN HUB…..745
CHECK FAN BELT TENSION…..745
EVERY 2000 HOURS SERVICE…..746
CLEAN HYDRAULIC TANK STRAINER…..746
CLEAN, CHECK TURBOCHARGER…..746
CHECK ALTERNATOR, STARTING MOTOR…..746
CHECK VIBRATION DAMPER…..747
CHANGE OIL IN AXLES…..747
CHANGE OIL IN HUBS…..748
CHANGE OIL IN TRANSMISSION ASSEMBLY…..748
CHANGE ANTIFREEZE…..748
CHECK AND ADJUST VALVE CLEARANCE…..748
EVERY 4000 HOURS SERVICE…..749
CHECK WATER PUMP…..749
EVERY 5000 HOURS SERVICE…..749
CHANGE OIL IN HYDRAULIC TANK…..749
SPECIFICATIONS…..754
SPECIFICATIONS…..755
1 – PIECE BOOM…..756
2 – PIECE BOOM…..757
WORKING RANGE: ONE PIECE BOOM…..758
WORKING RANGE: TWO PIECE BOOM…..759
OPTIONS, ATTACHMENTS…..762
GENERAL PRECAUTIONS…..763
PRECAUTIONS RELATED TO SAFETY…..763
PRECAUTIONS WHEN INSTALLING ATTACHMENTS…..764
HANDLING BUCKET WITH HOOK…..765
CHECKING FOR DAMAGE TO BUCKET WITH HOOK…..765
PROHIBITED OPERATIONS…..765
PRECAUTIONS DURING OPERATIONS…..765
MACHINES READY FOR ATTACHMENTS…..766
GENERAL LOCATIONS…..766
HANDLING THE CLAMSHELL BUCKET…..768
How to install clamshell bucket…..768
How to operate…..768
OPERATION…..769
WHEN USING BREAKER…..769
HANDLING ACCUMULATOR…..770
METHOD FOR RELEASING PRESSURE IN CONTROL CIRCUIT OF MACHINES EQUIPPED WITH ACCUMULATOR…..771
LONG-TERM STORAGE…..771
SPECIFICATIONS…..771
INTRODUCTION OF ATTACHMENTS AND EXTENDING MACHINE SERVICE LIFE…..773
HYDRAULIC BREAKER…..773
POWER RIPPER…..776
FORK GRAB…..777
GRAPPLE BUCKET…..778
SCRAP GRAPPLE…..779
CRUSHER & SMASHER…..781
HYDRAULIC PILE DRIVER…..782
HYDRAULIC EXCAVATOR WITH MULTIPURPOSE CRANE…..783
ROTATING ARM…..785
GENERAL LOCATION AND SPECIFICATIONS…..785
GENERAL VIEW OF CONTROLS…..786
LEFT WORK EQUIPMENT CONTROL LEVER (with auto-deceleration device)…..786
RIGHT WORK EQUIPMENT CONTROL LEVER (with auto-deceleration device)…..787
ARM ROTATION CONTROL…..787
UPPER BOOM CONTROL PEDAL…..788
PEDAL LOCK FOR BOOM ADJUST…..788
EXCAVATORS WORK…..788
REPLACEMENT OF BUCKET…..789
HANDLING THE TRAPEZOIDAL BUCKET (If equipped)…..790
TRAVELLING POSTURE…..791
MAINTENANCE REQUIREMENT…..793
EVERY 100 HOURS SERVICE…..793
EVERY 250 HOURS SERVICE…..793
EVERY 1000 HOURS SERVICE…..794

Komatsu Wheeled Excavator PW150 Repair Service Manuals


INSTANT DOWNLOAD


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Ford C-Max 2010-2016 Workshop Repair & Service Manual


INSTANT DOWNLOAD


Complete service repair manual with electrical wiring diagrams for Ford C-Max 2010-2016 (C-Max Energi SEL, C-Max Hybrid SE, C-Max Hybrid SEL), with all the shop information to maintain, diagnose, repair, and rebuild like professional mechanics.

Ford C-Max 2010-2016 workshop service & repair manual includes:
* Numbered table of contents easy to use so that you can find the information you need fast.
* Detailed sub-steps expand on repair procedure information
* Numbered instructions guide you through every repair procedure step by step.
* Troubleshooting and electrical service procedures are combined with detailed wiring diagrams for ease of use.
* Notes, cautions and warnings throughout each chapter pinpoint critical information.
* Bold figure number help you quickly match illustrations with instructions.
* Detailed illustrations, drawings and photos guide you through every procedure.
* Enlarged inset helps you identify and examine parts in detail.

PRODUCT DETAILS:
Total Pages: 3,221 pages
File Format: PDF (bookmarked, ToC, Searchable, Printable, high quality)
Language: English

FILE LIST:
ACCESSORIES & BODY, CAB Anti-Theft – Passive Anti-Theft System (Push Button Start).pdf
ACCESSORIES & BODY, CAB Anti-Theft – Passive Anti-Theft System.pdf
ACCESSORIES & BODY, CAB Anti-Theft Alarm – Perimeter.pdf
ACCESSORIES & BODY, CAB Body Closures.pdf
ACCESSORIES & BODY, CAB Body Panel System – Body Closures.pdf
ACCESSORIES & BODY, CAB Body Panel System – Body System – General Information.pdf
ACCESSORIES & BODY, CAB Body Panel System – Front End Body Panels.pdf
ACCESSORIES & BODY, CAB Body Repairs – General Information.pdf
ACCESSORIES & BODY, CAB Body Repairs – Specific Information.pdf
ACCESSORIES & BODY, CAB Body Repairs (General Information).pdf
ACCESSORIES & BODY, CAB Body Repairs (Tolerance Checks).pdf
ACCESSORIES & BODY, CAB Body System – General Information.pdf
ACCESSORIES & BODY, CAB Body System – Uni-Body, Subframe & Mounting System.pdf
ACCESSORIES & BODY, CAB Bumper System.pdf
ACCESSORIES & BODY, CAB Cruise Control.pdf
ACCESSORIES & BODY, CAB Exterior Lighting.pdf
ACCESSORIES & BODY, CAB Exterior Trim & Ornamentation.pdf
ACCESSORIES & BODY, CAB Front End Body Panels.pdf
ACCESSORIES & BODY, CAB Front End Sheet Metal Repairs.pdf
ACCESSORIES & BODY, CAB Front Seats.pdf
ACCESSORIES & BODY, CAB Handles, Locks, Latches & Entry Systems.pdf
ACCESSORIES & BODY, CAB Horn.pdf
ACCESSORIES & BODY, CAB Information & Entertainment Systems (W Touchscreen).pdf
ACCESSORIES & BODY, CAB Information & Entertainment Systems (WO Touchscreen).pdf
ACCESSORIES & BODY, CAB Instrument Panel & Console.pdf
ACCESSORIES & BODY, CAB Instrument Panel Cluster & Panel Illumination.pdf
ACCESSORIES & BODY, CAB Instrumentation, Message Center & Warning Chimes.pdf
ACCESSORIES & BODY, CAB Interior Lighting.pdf
ACCESSORIES & BODY, CAB Interior Trim & Ornamentation.pdf
ACCESSORIES & BODY, CAB Interior Trim And Ornamentation.pdf
ACCESSORIES & BODY, CAB Module Communications Network.pdf
ACCESSORIES & BODY, CAB Module Configuration.pdf
ACCESSORIES & BODY, CAB Multifunction Electronic Modules.pdf
ACCESSORIES & BODY, CAB Paint – General Information.pdf
ACCESSORIES & BODY, CAB Parking Aid System (W Active Park Assist).pdf
ACCESSORIES & BODY, CAB Parking Aid System.pdf
ACCESSORIES & BODY, CAB Rear End Sheet Metal Repairs.pdf
ACCESSORIES & BODY, CAB Rear Seats.pdf
ACCESSORIES & BODY, CAB Rear View Mirrors.pdf
ACCESSORIES & BODY, CAB Roof Sheet Metal Repairs.pdf
ACCESSORIES & BODY, CAB Side Panel Sheet Metal Repairs.pdf
ACCESSORIES & BODY, CAB Steering Column Switches.pdf
ACCESSORIES & BODY, CAB Universal Transmitter – Remote Convenience.pdf
ACCESSORIES & BODY, CAB Windows And Glass, Frames And Mechanisms.pdf
ACCESSORIES & BODY, CAB Wiper System & Washer System.pdf
BRAKES Anti-Lock Brake System & Stability Control System.pdf
BRAKES Brake System – General Information.pdf
BRAKES Front Disc Brake System.pdf
BRAKES Hydraulic Brake System Actuation.pdf
BRAKES Parking Brake System & Actuation.pdf
BRAKES Power Brake Actuation – Brake Booster.pdf
BRAKES Rear Disc Brake System.pdf
CABIN AIR FILTER Ford.pdf
DRIVELINEAXLES Driveline System – General Information.pdf
DRIVELINEAXLES Front Drive Halfshafts.pdf
DTC INDEX C-Max.pdf
ELECTRICAL Battery, Mounting & Cables.pdf
ELECTRICAL Charging System.pdf
ELECTRICAL High Voltage Battery Charging System.pdf
ELECTRICAL High Voltage Battery, Mounting & Cables.pdf
ELECTRICAL OEM Component Harness Location Charts Hybrid, C-MAX Energi.pdf
ELECTRICAL OEM Component Harness Location Views Hybrid, C-MAX Energi.pdf
ELECTRICAL OEM Connector End Views Hybrid, C-MAX Energi.pdf
ELECTRICAL OEM Connector Repair Procedures Hybrid, C-MAX Energi.pdf
ELECTRICAL OEM Electrical Wiring Diagram Introduction Hybrid, C-MAX Energi.pdf
ELECTRICAL OEM Fuse And Relay Information Hybrid, C-MAX Energi.pdf
ELECTRICAL OEM Ground Distribution Hybrid, C-MAX Energi.pdf
ELECTRICAL OEM Vehicle Repair Location Charts Hybrid, C-MAX Energi.pdf
ELECTRICAL OEM Wiring Diagram Symbols Hybrid, C-MAX Energi.pdf
ELECTRICAL OEM Wiring Diagrams Component Testing Hybrid, C-MAX Energi.pdf
ELECTRICAL OEM Wiring Diagrams Hybrid, C-MAX Energi 1.pdf
ELECTRICAL OEM Wiring Diagrams Hybrid, C-MAX Energi 2.pdf
ELECTRICAL Voltage ConverterInverter.pdf
ENGINE Acceleration Control.pdf
ENGINE Electric Powertrain Cooling.pdf
ENGINE Electronic Engine Controls.pdf
ENGINE Engine Cooling System.pdf
ENGINE Engine Emission Control System.pdf
ENGINE Engine Ignition System.pdf
ENGINE Engine Mechanical.pdf
ENGINE Engine System – General Information.pdf
ENGINE Evaporative Emissions System.pdf
ENGINE Exhaust System.pdf
ENGINE Fuel Charging & Controls.pdf
ENGINE Fuel System – General Information.pdf
ENGINE Fuel Tank & Fuel Lines.pdf
ENGINE Intake Air Distribution System & Filtering.pdf
ENGINE PERFORMANCE Engine Controls – Description & Operation (Hybrid).pdf
ENGINE PERFORMANCE Engine Controls – Diagnostic Methods (Hybrid).pdf
ENGINE PERFORMANCE Engine Controls – Introduction (Hybrid).pdf
ENGINE PERFORMANCE Engine Controls – Pinpoint Tests (Hybrid).pdf
ENGINE PERFORMANCE Engine Controls – Powertrain DTC Charts & Descriptions (Hybrid).pdf
ENGINE PERFORMANCE Engine Controls – Reference Values (Hybrid).pdf
ENGINE PERFORMANCE Engine Controls – Symptom Charts (Hybrid).pdf
ENGINE PERFORMANCE Firing Order & Cylinder Identification – Ford – All Models.pdf
ENGINE PERFORMANCE Mode 6 – Ford – Hybrid Electric Vehicles.pdf
GENERAL INFORMATION Anti-Lock Brake Safety Precautions.pdf
GENERAL INFORMATION Clutch Trouble Shooting.pdf
GENERAL INFORMATION Commonly Used Abbreviations.pdf
GENERAL INFORMATION Drive Axle Noise Diagnosis.pdf
GENERAL INFORMATION Engine Displacement Conversion Table.pdf
GENERAL INFORMATION Engine Overhaul Procedures.pdf
GENERAL INFORMATION English-Metric Conversion Chart.pdf
GENERAL INFORMATION Gear Tooth Contact Patterns.pdf
GENERAL INFORMATION General Cooling System Service.pdf
GENERAL INFORMATION General Information.pdf
GENERAL INFORMATION Jacking & Lifting.pdf
GENERAL INFORMATION Maintenance Schedule.pdf
GENERAL INFORMATION Manual Transmission Trouble Shooting.pdf
GENERAL INFORMATION Noise, Vibration & Harshness.pdf
GENERAL INFORMATION Symptom Check List Worksheets.pdf
GENERAL INFORMATION Trouble Shooting – Basic Procedures.pdf
GENERAL INFORMATION TROUBLE SHOOTING.pdf
GENERAL INFORMATION VIN – Identification Codes.pdf
GENERAL INFORMATION Waveforms – Injector Pattern Tutorial.pdf
GENERAL INFORMATION Wheel Alignment Theory & Operation.pdf
HVAC Auxiliary Climate Control.pdf
HVAC Climate Control System.pdf
OBD-II Readiness Monitors Ford – 2013.pdf
REMINDER INDICATOR RESET PROCEDURES Ford  Lincoln  Mercury – 1985-14.pdf
RESTRAINTS Safety Belt System.pdf
RESTRAINTS Supplemental Restraint System.pdf
STEERING Power Steering System.pdf
STEERING Steering Column.pdf
SUSPENSION FORD WHEEL ALIGNMENT SPECIFICATIONS.pdf
SUSPENSION Front Suspension.pdf
SUSPENSION Rear Suspension.pdf
SUSPENSION Suspension System – General Information.pdf
SUSPENSION Tire Pressure Monitoring System.pdf
SUSPENSION Wheels & Tires.pdf
SYSTEM WIRING DIAGRAMS Ford.pdf
TIRE PRESSURE MONITOR SYSTEMS Ford – Ford – 2013.pdf
TRACTION CONTROL, 4WD, & AWD Ford – 1980-14.pdf
TRANSMISSIONS Automatic Transaxle Cooling.pdf
TRANSMISSIONS Automatic Transaxle External Controls.pdf
TRANSMISSIONS Automatic Transaxle.pdf
UNIFORM INSPECTION & COMMUNICATION STANDARDS 2010 – 2011 Routine Inspection Reference Guide.pdf
UNIFORM INSPECTION & COMMUNICATION STANDARDS 2010 – 2011 Steering & Suspension Systems.pdf

Ford C-Max 2010-2016 Repair Service Manual


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